Tray configured for packaging, packaged product assembly, and method for packaging a product

ABSTRACT

A tray configured for packaging is provided. The tray may include a substantially planar portion and a curved perimeter portion extending from the substantially planar portion. One or more cutout portions may be defined in the substantially planar portion. The tray may also include a handle that may be grasped during insertion into, or removal from a rear cover of an accessory unit. In this regard, the substantially planar portion and the curved perimeter portion of the tray may support a recessed portion of the rear cover of the accessory unit when received therein. Thus, issues with respect to deformation of the recessed portion, which may be formed from a flexible material, may be avoided. The tray may be part of a packaging system that further includes a box and a lid.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/618,523, filed Mar. 30, 2012, and entitled “TRAY CONFIGURED FOR PACKAGING, PACKAGED PRODUCT ASSEMBLY, AND METHOD FOR PACKAGING A PRODUCT,” and which is incorporated by reference herein in its entirety for all purposes.

TECHNICAL FIELD

The present disclosure relates generally to packaging for products, and more particularly to methods, apparatuses, and assemblies for packaging products.

BACKGROUND

Competition in the consumer products markets has led manufacturers to improve not only the products they sell, but also the packaging therefor. In this regard, appealing retail packaging may encourage purchase of products that a consumer may otherwise overlook. Accordingly, design considerations for packaging have become increasingly more important.

In addition to having aesthetic appeal, packaging should protect the product such that it is not damaged or deformed during shipping. Regardless of whether or not the deformation is reversible, a user may prefer that a product arrive in an undeformed condition. While many designs and techniques used to package products have generally worked well in the past, there is always a desire to improve packaging, such that improved functionality and/or appearance is provided.

SUMMARY

An accessory unit for a consumer electronic device may include a rear cover that may receive the consumer electronic device therein, and a front flap that pivots relative thereto to either allow for use of the consumer electronic device or protect a screen thereof. The recessed portion of the accessory unit may be formed from a flexible material such that it conforms to the shape of the consumer electronic device. However, during shipping or handling thereof it may be possible for the recessed portion of the rear cover to become deformed as a result of forces applied thereto.

Accordingly, the present disclosure provides a tray that is configured for packaging an accessory unit. In this regard, the tray may include a substantially planar portion and a curved perimeter portion that are respectively configured to support a bottom wall and a sidewall of the recessed portion of the accessory unit. For example, the substantially planar portion and the curved perimeter portion may be sized and shaped similarly to the bottom wall and the sidewall of the recessed portion of the accessory unit. The curved perimeter portion may extend to a rim that engages a frame coupled to the recessed portion of the accessory unit such that the tray is retained in the recessed portion.

The substantially planar portion of the tray may have cutout portions therein. The cutout portions may allow a consumer to view through the tray such that the consumer is quickly able to determine that the tray is a piece of packaging materials that should be discarded, as opposed to a portion of the accessory unit itself. In some embodiments, the cutout portions may also extend through the curved perimeter portion of the tray such that the tray defines flaps that extend from a center section. Further, score lines may be provided that extend between the cutout portions and facilitate folding of the flaps such that insertion and removal of the tray with respect to the recessed portion of the accessory unit may be facilitated. A handle feature such as a pull-tab or a raised portion with an aperture therethrough may also assist the user during insertion or removal of the tray.

A packaging system for the accessory unit may include a box and lid, in addition to the tray. Thereby, the tray may be inserted into the recessed portion of the accessory unit, and the accessory unit may then be inserted into the box and the lid closed. Accordingly, a packaged product assembly may mitigate deformation of the recessed portion of the accessory unit that may otherwise occurring during shipping or handling of the accessory unit.

Other apparatuses, methods, features and advantages of the disclosure will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The included drawings are for illustrative purposes and serve only to provide examples of possible structures and arrangements for the disclosed trays, packaging systems, packaged product assemblies, and methods for packaging. These drawings in no way limit any changes in form and detail that may be made to the disclosure by one skilled in the art without departing from the spirit and scope of the disclosure.

FIG. 1 illustrates a top view of a tray configured for packaging comprising a pull-tab and cutout portions in a substantially planar portion according to a first example embodiment of the present disclosure;

FIG. 2 illustrates a side view of the tray of FIG. 1;

FIG. 3 illustrates a top view of a tray configured for packaging comprising a raised portion with an aperture therethrough and cutout portions in a substantially planar portion according to a second example embodiment of the present disclosure;

FIG. 4 illustrates a top view of a tray configured for packaging comprising a raised portion with an aperture therethrough and cutout portions in a substantially planar portion and a curved perimeter portion according to a third example embodiment of the present disclosure;

FIG. 5 illustrates a bottom view of the tray of FIG. 4;

FIG. 6 illustrates a perspective view of the tray of FIG. 4 in a folded configuration;

FIG. 7 illustrates a perspective view of an accessory unit that may be packaged in accordance with example embodiments of the present disclosure;

FIG. 8 illustrates a partial top view of the accessory unit of FIG. 7 with the tray of FIG. 4 received therein;

FIG. 9 illustrates a sectional view through the accessory unit and tray of FIG. 8;

FIG. 10 illustrates a perspective view of a packaging system including a box and a lid according to an example embodiment of the present disclosure;

FIG. 11 illustrates a top perspective view of a packaged product assembly including the packaging system of FIG. 10 in an open configuration and the accessory unit of FIG. 7 received therein according to an example embodiment of the present disclosure;

FIG. 12 illustrates a bottom perspective view of the packaged product assembly of FIG. 11 in a partially assembled configuration;

FIG. 13 illustrates a bottom view of the packaged product assembly of FIG. 11 in a fully assembled configuration;

FIG. 14 illustrates a method for packaging according to an example embodiment of the present disclosure;

FIG. 15 schematically illustrates a cross-sectional view through a tray comprising multiple layers of material in which an upper layer defines a handle feature according to a fourth example embodiment of the present disclosure;

FIG. 16 schematically illustrates a cross-sectional view through a tray comprising multiple layers of material in which a lower layer defines a handle feature according to a fifth example embodiment of the present disclosure; and

FIG. 17 illustrates a top schematic view of a tray in which a second layer is selectively included at desired locations according to a sixth example embodiment of the present disclosure.

DETAILED DESCRIPTION

Exemplary applications of apparatuses, assemblies, systems, and methods according to the present disclosure are described in this section. These examples are being provided solely to add context and aid in the understanding of the disclosure. It will thus be apparent to one skilled in the art that the present disclosure may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the present disclosure. Other applications are possible, such that the following examples should not be taken as limiting.

Improved packaging that protects a product is desirable. Thus, a consumer may be presented with a product in new and undamaged condition. Improved aesthetic appeal for packaging also remains desirable, particularly when the packaging is employed for retail sale of a product. Further, packaging that simplifies the process for accessing the product may also be desirable to consumers.

In this regard, FIG. 1 illustrates a top view of a first embodiment of a tray 100A configured for packaging. As discussed below, the tray 100A may be configured to provide support to an accessory unit by acting as internal packaging therefor. The tray 100A may comprise a substantially planar portion 102A. One or more cutout portions 104A may be defined in the substantially planar portion 102A. The cutout portions 104A decrease the weight of the tray 100A so as to reduce the shipping cost associated with shipping the tray and any product supported thereby. Further, the cutout portions 104A allow a consumer to view through the tray 100A. Accordingly, the consumer may be provided with an indication that the tray 100A is a piece of packaging material, rather than a component of the accessory unit that the tray supports. Thus, a consumer may not improperly attempt to attach the accessory unit to a consumer electronic device with the tray still therein.

The tray 100A may further comprise a curved perimeter portion 106A that extends from the substantially planar portion 102A. In the embodiment of the tray 100 illustrated in FIG. 1, the curved perimeter portion 106A surrounds the substantially planar portion 102A. Further, the curved perimeter portion 106A extends to a rim 108A.

The tray 100A may additionally include a handle feature 110A. The handle feature 110A may be configured for grasping the tray 100A during insertion into, or removal from, an accessory unit. In the embodiment of the tray 100A illustrated in FIG. 1, the handle feature 110A comprises a pull-tab 112A. The pull-tab 112A may comprise a semicircular piece of material that is formed by cutting the substantially planar portion 102A along a semicircular line 114A. To provide a pleasing aesthetic appearance, a corresponding debossed semicircle 116A may be positioned next to the pull-tab 112A. Thus, the pull-tab 112A and the debossed semicircle 116A may combine to form a circular shape. In this regard, the cutout portions 104A may define circular shapes of the same size as the circle defined by the pull-tab 112A and the debossed semicircle 116A in some embodiments. Further, a score line 118A may be provided between the debossed semicircle 116A and the pull-tab 112A. The score line 118A may encourage the pull-tab 112A to fold cleanly therealong.

As illustrated in FIG. 2, which is a side view of the embodiment of the tray 100A illustrated in FIG. 1, the rim 108A may define a flange 120A in some embodiments. The flange 120A may be provided in order to simplify production of the tray 100A. In this regard, the flange 120A may define a planar configuration that is more easily cut than a curved surface. Accordingly, the flange 120A may reduce costs associated with production of the tray 100A. However, the trays disclosed herein may not include a planar flange in all embodiments.

The tray 100A may be formed from a variety of materials. However, in one embodiment the tray 100A may comprise a molded fiber material. The molded fiber material may define a smooth inner surface 122A (see, e.g., FIG. 1), which may be aesthetically pleasing to a consumer. Further, the molded fiber material may define a mesh pattern at an outer surface 124A (see, e.g., FIG. 2) thereof. The patterned outer surface 124A may be configured to engage the inner surface of an accessory unit such that the tray 100A remains properly positioned therein. The mesh defining the patterned outer surface 124A may also provide the molded fiber material with additional strength and rigidity.

Various other embodiments of trays are also provided. The additional embodiments of trays may include many of the features of the first embodiment of a tray 100A illustrated in FIGS. 1 and 2. Accordingly, features that are substantially similar may not be discussed for purposes of brevity. Similar features are indicated by similar reference numerals.

FIG. 3 illustrates a top view of a second embodiment of a tray 100B configured for packaging. In one aspect, the tray 100B differs from the above-described embodiment of a tray 100A in the position and shape of the cutout portions 104B in the substantially planar portion 102B. However, the cutout portions 104B may serve the same purpose of reducing weight and allowing a consumer to view through the tray 100B portions.

The handle feature 110B of the tray 100B also differs. As illustrated, the handle feature 110B comprises a raised portion 126B with an aperture 128B therethrough. The raised portion 126B may include a substantially planar ring 130B that surrounds the aperture 128B. The raised portion 126B of the handle feature 110B may define an annular pocket that is accessible through the aperture 128B. Thereby, a user may be able to grasp the tray 100B my extending one or more fingers through the aperture 128B and curl his or her fingers into contact with the outer surface 124B of the tray (e.g., at the substantially planar ring 130B of the raised portion 126B). Additionally, the user may press his or her thumb against the inner surface 122B of the tray 100B (e.g., at the raised portion 126B or the substantially planar portion 100B) in order to stabilize the tray while grasping the handle feature 110B.

A third embodiment of a tray 100C configured for packaging is illustrated in FIG. 4. The tray 100C includes many of the features discussed above with respect to the second embodiment of the tray 100B. For example, the tray 100C includes an embodiment of the handle feature 110C with a raised portion 126C having a substantially planar ring 130C that surrounds an aperture 128C. As illustrated in FIG. 5, which is a rear perspective view of the tray 100C, the raised portion 126C may define an annular pocket 132C at the outer surface 124C of the tray that is accessible through the aperture 128C, as described above.

However, the cutout portions 104C of the tray 100C differ from the above-described embodiments of cutout portions. In particular, the cutout portions 104C extend not only through the substantially planar portion 102C, but also through the curved perimeter portion 106C. Extending the cutout portions 104C through the curved perimeter portion 106C may provide the tray 100C with additional flexibility, which may assist a user in installing the tray in, and removing the tray from, an accessory unit.

The tray 100C additionally includes a plurality of score lines 134C defined in the substantially planar portion 102C. As illustrated, the score lines 134C may extend between the cutout portions 104C around the handle feature 110C. Thus, the score lines 134C may divide the substantially planar portion 102C into a center section 136C, which may surround the handle feature 110C, and a plurality of flaps 138C that are foldable relative to the center section. The flaps 138C may also respectively include portions of the curved perimeter portion 106C extending therefrom.

As illustrated in FIG. 6, the score lines 134C may facilitate folding of the substantially planar portion 102C therealong such that when the flaps 138C are folded, the substantially planar portion 102C may cleanly bend therealong. The folded configuration of the flaps 138C illustrated in FIG. 6 may be employed to facilitate insertion of the tray 100C into an accessory unit.

In this regard, FIG. 7 illustrates an example embodiment of an accessory unit 200 for a consumer electronic device that may be supported by the embodiments of the trays 100A-C (collectively, “100”) disclosed herein. By way of example, the accessory unit 200 may comprise an embodiment of an accessory unit disclosed in U.S. patent application entitled, “ACCESSORY UNITS FOR CONSUMER ELECTRONIC DEVICES AND RELATED ASSEMBLIES AND METHODS” by Balaji et. al. filed Mar. 6, 2012 having Application No. PCT/US2012/027921 which is incorporated herein by reference in its entirety. However, the trays 100 may be employed to support various other embodiments of accessory units.

As illustrated, the accessory unit 200 may comprise a front flap 202 and a rear cover 204. The front flap 202 may include a plurality of segments 206 and a folding region 208 positioned between each of the segments. The folding regions 208 may be configured to allow the segments 206 to fold with respect to each other. The front flap 202 may also include an end region 210. The end region 210 hingedly couples the front flap 202 to the rear cover 204.

The rear cover 204 may include a recessed portion 212 and a frame 214. The recessed portion 212 may include a plurality of sidewalls 216 and a bottom wall 218 that collectively define a chamber 220. The frame 214 may be coupled to the recessed portion 212 and extend about an opening 222 of the chamber 220. The recessed portion 212 of the rear cover 204 may be formed from a flexible material. Additionally, the frame 214 may be formed from a material that is more rigid than the flexible material of the recessed portion 212. In this regard, the frame 214 of the rear cover 204 may be configured to retain a consumer electronic device in the chamber 220.

Due to the recessed portion 212 of the rear cover 204 of the accessory unit 200 being formed from a flexible material, it may be possible for the recessed portion to collapse, dent, or otherwise become deformed when a consumer electronic device is not held therein. For example, during shipment of the accessory unit 200, the accessory unit may be compressed or otherwise subjected to forces that affect the shape of the recessed portion 212.

Accordingly, the trays 100 discussed herein may be employed as packaging configured to support the accessory unit 200. In this regard, FIG. 8 illustrates the accessory unit 200 with the front flap 202 in an open configuration and the third embodiment of the tray 100C is received in the rear cover 204. However, as noted above, other embodiments of trays 100 may be employed to support the accessory unit 200.

As illustrated in FIG. 8, the tray 100C may be received in the recessed portion 212 of the rear cover 204. In particular, the substantially planar portion 102C and the curved perimeter portion 106C of the tray 100C may engage the recessed portion 212 of the rear cover 204. For example, the curved perimeter portion 106C of the tray 100C may engage and support the sidewalls 216 of the recessed portion 212. Further, the substantially planar portion 102C may engage and support the bottom wall 218 of the recessed portion 212.

FIG. 9 illustrates a cross-sectional view through the accessory unit 200 when the tray 100C is received therein and the front flap 202 is in a closed position. As illustrated, the rim 108C of the curved perimeter portion 106C may engage an inner edge 224 of the frame 214. Thus, the frame 214 may retain the tray 100C inside the recessed portion 212 of the rear cover 204.

Accordingly, each of the above-described embodiments of a tray 100 may function to support the accessory unit 200 by respectively engaging the bottom wall 218 and the sidewalls 216 of the recessed portion 212 of the rear cover 204 with the similarly shaped substantially planar portion 102 and curved perimeter portion 106 of the trays. Thus, each embodiment of the tray 100 may resist deformation of the recessed portion 212 of the rear cover 204 by providing support thereto.

In some embodiments it may be desirable to provide the trays 100 with dimensions that are greater than the dimensions of the opening 222 to the chamber 220 defined in the recessed portion 212 of the rear cover 204. Thus, when the tray 100 is received in the chamber 220, the frame 214 may retain the tray therein such that the recessed portion 212 remains supported. For example, as noted above, the rim 108 of the curved perimeter portion 106 may engage the inner edge 224 of the frame 214.

However, the third embodiment of the tray 100C provides additional functionality. In this regard, as noted above, the score lines 134C divide the substantially planar portion 102C into the center section 136C, which may surround the handle feature 110C, and a plurality of flaps 138C that are foldable relative to the center section. The flaps 138C may also respectively include sections of the curved perimeter portion 106C. As illustrated in FIG. 6, each of the flaps 138C may fold along the score lines 134C. By facilitating folding in this manner, the score lines 134C may make it easier to insert the tray 100C through the frame 214 into the compartment 220 by allowing the tray to bend during insertion. Further, the flaps 138C may facilitate removal of the tray 100C from the accessory unit 200 by allowing the flaps to fold in an opposite manner as a consumer withdraws the tray from the compartment 220. In this regard, the score lines 134C may be particularly advantageous in embodiments of the tray 100C that define dimensions greater than that of the opening 222 to the compartment 220. For example, when the flaps 138C are folded down and inwardly, the dimensions of the tray 100C (e.g., length and width) may be decreased such that the tray fits through the opening 222. As the flaps 138C are inserted through the frame 214, the flaps may unfold into a substantially planar configuration.

Use of oversized dimensions of the tray 100 may also function to retain the tray in the recessed portion 212 of the rear cover 204 of the accessory unit 200 when the accessory unit and the tray are subjected to changes in temperature. For example, changes in temperature may cause the tray 100 to shrink relative to the accessory unit 200. Accordingly, use of oversized dimensions may allow the tray 100 to retain a sufficient size to remain engaged with the recessed portion 212 of the rear cover 204 despite the relative shrinkage.

Further, embodiments of the tray 100 (e.g. tray 100B and tray 100C) including a handle feature 110 with a raised portion 126 may provide additional benefits. In this regard, the raised portion 126 of the handle feature 110 may be provided with a height that is slightly greater than a height to which the curved perimeter portion 106 extends. For example, FIG. 9 illustrates an embodiment of the tray 100C in which the raised portion 126C of the handle feature 110C extends to a height 140C that is slightly greater than a height 142C to which the curved perimeter portion 106C extends. Accordingly, whereas the rim 108C of the curved perimeter portion 106C comes into contact with the inner edge 224 of the frame 214 of the accessory unit 200, the raised portion 126C may contact the front flap 202 of the accessory unit when the front flap is in the closed configuration. For example, in some embodiments the height 140C of the handle feature 110C may be greater than or equal to a height 226 of the rear cover 204. Thus, force applied to the bottom wall 218 of the rear cover 204 may be transferred through the handle feature 110C to the front flap 202, due to the raised portion 126C being in contact therewith. Thereby, deformation of the recessed portion 212 of the accessory unit 200 may be avoided.

Further, in embodiments of the tray 100C employing the score lines 134C and enlarged dimensions relative to the compartment 220 defined by the recessed portion 212 of the rear cover 204, the center section 136C of the tray may be lifted slightly relative to the flaps 138C and the bottom wall 218 of the recessed portion. This may assist in providing the raised portion 126C with a greater height 140C than the height 142C of the curved perimeter portion 106C. Further, this configuration may provide the tray 100C with a spring bias that applies pressure to the bottom wall 218 of the rear cover 204 when the front flap 202 is closed and thereby brought into contact with the raised portion 126C of the tray 100C. Accordingly, the spring bias may further resist deformation of the recessed portion 212.

In order to further protect the accessory unit 200 from damage, additional packaging may be provided. In this regard, FIG. 10 illustrates an embodiment of a packaging system 300 in an open configuration. The packaging system 300 may incorporate some or all of the features of the embodiments of packaging systems disclosed in U.S. patent application entitled, “PACKAGING ASSEMBLY” by Akana et. al. filed Mar. 9, 2012 having application Ser. No. 13/416,855 which is incorporated herein by reference in its entirety. However, various other embodiments of packaging systems may be employed in other embodiments.

Briefly, the packaging system 300 may comprise a box 302 and a lid 304. The packaging system 300 may also include an embodiment of the tray 100, although not illustrated in FIG. 10. In one example embodiment the box 302 may comprise one or more layers of cardboard, paperboard, paper, and/or other materials that are folded, glued, and/or otherwise formed into a plurality of walls. In particular, the walls may include a bottom wall 306 and a plurality of sidewalls 308. The sidewalls 308 and the bottom wall 306 may define an interior compartment 310 that is configured to receive a product such as the above-described accessory unit 200. The sidewalls 308 may define an upper opening 312 to the interior compartment 310 opposite the bottom wall 306. Further, a slot 314 may be defined in the bottom wall 306.

The lid 304 may be hingedly coupled to the box 302. In some embodiments the lid 304 and the box 302 may be integrally formed and/or formed from the same material. However, in other embodiments the lid 304 and the box 302 may be separate components formed from different materials. In this regard, in some embodiments the lid 304 may comprise a plastic material such as polyethylene terephthalate (PET). Embodiments of plastic materials that are translucent or transparent may be advantageously employed to form all or a part of the lid 304 in embodiments of the packaging system 300 employed for retail sales, since consumers may thereby be able to view a product therethrough. The lid 304 may comprise a major panel 316 and a plurality of side panels 318 with score lines 320 therebetween, which may be formed by radio frequency (RF) scoring in some embodiments. In order to hingedly couple the lid 304 to the box 302, one of the side panels 318 of the lid may be coupled to one of the sidewalls 308 of the box. Accordingly, the lid 304 may pivot between an open configuration (see, e.g., FIG. 10) in which the upper opening 312 of the box 302 is open and a closed configuration (see, e.g., FIG. 11) in which the lid covers the upper opening.

The lid 304 may additionally include a tab 322 in some embodiments. The tab 322 may extend from one of the side panels 318 that is opposite to the one of the side panels hingedly coupled to one of the sidewalls 308 of the box 302. Accordingly, the tab 322 may align with the slot 314 in the bottom wall 306 of the box 302 when the lid 304 is folded to the closed configuration.

The packaging system 300 may further comprise an adhesive member 324 coupled to the tab 322 defined by the lid 304. In some embodiments the adhesive member 324 may comprise a first flap 326 (see, e.g., FIGS. 10 and 12) and a second flap 328 (see, e.g., FIG. 13) with adhesive on inner surfaces thereof that couple the flaps to the tab 322. Further, an extension 330 may extend from the first and second flaps 326, 328.

FIG. 11 illustrates a packaged product assembly 400 comprising the packaging system 300 and the accessory unit 200 received in the interior compartment 310 of the box 302. An embodiment of the tray 100 may be received in the rear cover 204 of the accessory unit 200 such that the recessed portion 212 thereof is supported by the substantially planar portion 102 and curved perimeter portion 106 of the tray. Further, the front flap 202 of the accessory unit 200 may be configured in the closed configuration (see, e.g., FIG. 9). After the accessory unit 200 and tray 100 are received in the interior compartment 310 of the box 302, the lid 304 may be configured to the closed configuration illustrated in FIG. 11 in which the lid covers the upper opening 312 of the box.

As the lid 304 is configured to the closed configuration, the tab 322 and the adhesive member 324 may align with the slot 314 defined in the bottom wall 306 of the box 302 as the lid and the box are pivoted toward one another. Accordingly, as illustrated in FIG. 12, the tab 322 and the adhesive member 324 may extend through the slot 314 defined in the bottom wall 306 of the box 302 when the lid 304 is pivoted to the closed configuration. The adhesive member 324 may further comprise an adhesive at an outer surface 332 of the first flap 326. The adhesive member 324 may also include an adhesive liner 334, which is shown as partially removed in FIG. 12, coupled to the adhesive at the outer surface 332. The adhesive liner 334 may prevent the adhesive from adhering to the bottom wall 306 of the box 302 as the adhesive member 324 is inserted through the slot 314.

After the tab 322 and the adhesive member 324 are inserted through the slot 314 defined in the bottom wall 306 of the box 302, the adhesive liner 334 may be removed such that the adhesive at the outer surface 332 of the first flap 326 is exposed. The tab 322 may then be bent about a score line 336 (see, e.g., FIG. 10). Accordingly, the adhesive at the outer surface 332 of the first flap 326 of the adhesive member 324 may couple the tab 322 to an outer surface of the bottom wall 306 of the box 302, as illustrated in FIG. 13. Thereby, the lid 304 may be retained in the closed configuration.

In the closed configuration, the various parts of the packaging system 300 cooperate to protect the accessory unit 200 from damage. In this regard, the box 302 and the lid 304 may function to protect the accessory unit 200 from external damage. Further, the tray 100 functions to prevent the recessed portion 312 of the rear cover 204 of the accessory unit 200 from deforming. The box 302 and the lid 304 may also assist in preventing deformation of the recessed portion 312. For example, in embodiments of the tray 100 including a handle feature 110 with a raised portion 126, the box 302 and the lid 304 may restrain movement of the front flap 202 relative to the rear cover 204 of the accessory unit 200, such that the packaging assembly resists force transferred from the recessed portion 212 of the rear cover 204 through the tray 100 to the front flap such that the front flap remains in the closed configuration. Accordingly, the box 302 and the lid 304 assist in resisting deformation of the recessed portion 212 of the rear cover 204 of the accessory unit.

In order to access the accessory unit 200 from the packaged product assembly 400, a consumer may grasp the extension 330 of the adhesive member 324, which is decoupled from the bottom wall 306 of the box 302 because it does not include an adhesive, in order to detach the adhesive member from the box. Thereafter, a consumer may perform the above-noted operations performed in assembling the packaged product assembly substantially in reverse order. However, various ones of the above-noted steps need not be conducted. For example, after the consumer detaches the adhesive member 324 from the bottom wall 306 of the box 302, he or she may simply push the adhesive member and the tab 322 back through the slot 314 without detaching the adhesive member from the tab.

The consumer may then pivot the lid 304 relative to the box 302 such that the lid reaches the open configuration in which the upper opening 312 to the interior compartment 310 of the box is open. The consumer may then remove the accessory unit 200 from the box 302 and pivot the front flap 202 to the open configuration. The handle feature 110 may then be employed to lift the tray 100 from accessory unit 200. Accordingly, a user may unpackage the accessory unit 200 in a relatively simple manner. In this regard, scissors or other tools may not be required to retrieve the accessory unit 200 from the packaging system 300 or remove the tray 100.

A related method for packaging is also provided. As illustrated in FIG. 14, the method may include providing an accessory unit at operation 502. The accessory unit may comprise the above-described embodiment of an accessory unit 200 described above. In this regard, the accessory unit may comprise a front flap and a rear cover. However, various other embodiments of accessory units may be packaged in other embodiments.

The method may further comprise providing a tray at operation 502. The tray may comprise one of the above-described trays 100 in some embodiments. In this regard, the tray may comprise a substantially planar portion, a curved perimeter portion extending from the substantially planar portion, a plurality of cutout portions in the substantially planar portion, and a handle feature configured for grasping the tray.

The method may additionally include inserting the tray into the rear cover of the accessory unit at operation 504. Inserting the tray into the rear cover at operation 504 may comprise inserting the tray through a frame coupled to the rear portion of the accessory unit. Further, inserting the tray through the frame coupled to the recessed portion may comprise folding the substantially planar portion of the tray at a plurality of score lines extending between the cutout portions around the handle feature. As a result of insertion of the tray at operation 504, the substantially planar portion and the curved perimeter portion of the tray may support the accessory unit by engaging the recessed portion of the rear cover.

The method may also include pivoting the front flap relative to the rear cover to a closed configuration at operation 506. Pivoting the front flap relative to the rear cover at operation 506 may comprise engaging the front flap with the handle feature of the tray.

In some embodiments the method may additionally include providing a box comprising a plurality of walls defining an interior compartment and inserting the accessory unit in to the interior compartment of the box. Further, the method may include providing a lid coupled to one of the walls of the box and pivoting the lid relative to the box to a closed configuration in which the lid covers an upper opening of the box.

In some embodiments the trays 100 described herein may comprise a single layer of the above-described molded fiber material. In another embodiment the trays 100 may comprise two or more layers of material (e.g., the molded fiber material) that are glued or otherwise coupled together. The two layers may define differing properties, such as material composition and/or geometry. Thereby, the properties of the tray 100 at the inner and outer surfaces may be separately controlled as desired. For example, differing material properties of the two layers may be employed to provide the tray 100 with a balance of support and flexibility. Further, some embodiments of materials may have limits with respect to the thickness of a single layer thereof. Thus, in order to make the tray 100 thicker, multiple layers of material may be required.

In this regard, FIG. 15 schematically illustrates a cross-sectional view through an embodiment of a tray 100D comprising multiple layers 144D, 146D of material. The upper layer 144D may define a handle feature 110D with a raised portion 126D having a substantially planar ring 130D that surrounds an aperture 128D. Accordingly, the tray 100D may be lifted via the handle feature 110D as discussed above. The lower layer 146 coupled thereto may be configured as needed to produce desired properties. For example, if more strength is required, the lower layer 146D may be substantially continuous. Further, as illustrated, the lower layer 146D may not include a raised portion, and thus the separation of the layers 144D, 146D at the handle features 110D may define a three-dimensional structure that provides the tray 100D with extra support.

FIG. 16 schematically illustrates a cross-sectional view through an alternate embodiment of the tray 100E in which the upper layer 144E defines an aperture 148E. The aperture 148E in the upper layer 144E may be configured to align with a handle feature 110E defined by the lower layer 146E. In this regard, during assembly of the tray 100E, the raised portion 126E of the lower layer 146E may mate with the aperture 148E in the upper layer 144E to cause the two layers to self-align.

FIG. 17 illustrates a top schematic view of an alternate embodiment of the tray 100F in which a second layer is selectively included at desired locations. Thereby, for example, the tray 100F may be provided with additional rigidity at the areas where the second layer is applied, and relatively greater flexibility where the second layer is not applied. In the illustrated embodiment, the tray 100F includes a lower layer 146F with an upper layer 144F applied at each of the flaps 138F. Thereby, each flap 138F is individually stiffened, but each flap may still easily flex relative to the center section 136F.

Although the foregoing disclosure has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described disclosure may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the disclosure. Certain changes and modifications may be practiced, and it is understood that the disclosure is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims. 

What is claimed is:
 1. A tray configured for packaging, the tray comprising: a substantially planar portion; a curved perimeter portion extending from the substantially planar portion; a plurality of cutout portions in the substantially planar portion; and a handle feature configured for grasping, wherein the substantially planar portion and the curved perimeter portion are configured to support an accessory unit comprising a front flap and a rear cover by engaging a recessed portion of the rear cover.
 2. The tray of claim 1, wherein the handle feature comprises a pull-tab.
 3. The tray of claim 1, wherein the handle feature comprises a raised portion with an aperture therethrough, wherein the raised portion is configured to engage the front flap of the accessory unit when the front flap is in a closed configuration.
 4. The tray of claim 3, wherein the raised portion defines an annular pocket that is accessible through the aperture.
 5. The tray of claim 1, further comprising a plurality of score lines extending between the cutout portions around the handle feature.
 6. The tray of claim 5, wherein the score lines divide the substantially planar portion into a center section surrounding the handle feature and a plurality of flaps foldable relative to the center section.
 7. The tray of claim 1, wherein the cutout portions extend through the curved perimeter portion.
 8. A packaged product assembly, comprising: a box comprising a plurality of walls defining an interior compartment; an accessory unit received in the interior compartment of the box, the accessory unit comprising a front flap and a rear cover having a recessed portion; and a tray received in the rear cover of the accessory unit, the tray comprising: a substantially planar portion; a curved perimeter portion extending from the substantially planar portion; a plurality of cutout portions in the substantially planar portion; and a handle feature configured for grasping, wherein the front flap is configured in a closed position and the substantially planar portion and the curved perimeter portion of the tray support the accessory unit by engaging the recessed portion of the rear cover.
 9. The packaged product assembly of claim 8, further comprising a lid coupled to one of the walls of the box and configured in a closed configuration in which the lid covers an upper opening of the box.
 10. The packaged product assembly of claim 9, further comprising an adhesive member coupled to a tab defined by the lid, wherein the tab is received through a slot defined in a bottom wall of the box and the adhesive member is releasably engaged to an outer surface of the bottom wall such that the lid is retained in the closed configuration.
 11. The packaged product assembly of claim 8, wherein the handle feature comprises a pull-tab.
 12. The packaged product assembly of claim 8, wherein the handle feature comprises a raised portion with an aperture therethrough, wherein the raised portion engages the front flap of the accessory unit.
 13. The packaged product assembly of claim 12, wherein the raised portion defines an annular pocket that is accessible through the aperture.
 14. The packaged product assembly of claim 8, further comprising a plurality of score lines extending between the cutout portions around the handle feature.
 15. The packaged product assembly of claim 14, wherein the score lines divide the substantially planar portion into a center section surrounding the handle feature and a plurality of flaps foldable relative to the center section.
 16. The packaged product assembly of claim 8, wherein the cutout portions extend through the curved perimeter portion.
 17. A method for packaging, comprising: providing an accessory unit comprising a front flap and a rear cover having a recessed portion; providing a tray comprising: a substantially planar portion; a curved perimeter portion extending from the substantially planar portion; a plurality of cutout portions in the substantially planar portion; and a handle feature configured for grasping; inserting the tray into the rear cover of the accessory unit such that the substantially planar portion and the curved perimeter portion support the accessory unit by engaging the recessed portion of the rear cover; and pivoting the front flap relative to the rear cover to a closed configuration.
 18. The method of claim 17, further comprising providing a box comprising a plurality of walls defining an interior compartment; and inserting the accessory unit into the interior compartment of the box.
 19. The method of claim 18, further comprising providing a lid coupled to one of the walls of the box; and pivoting the lid relative to the box to a closed configuration in which the lid covers an upper opening of the box.
 20. The method of claim 17, wherein pivoting the front flap relative to the rear cover comprises engaging the front flap with the handle feature.
 21. The method of claim 17, wherein inserting the tray into the rear cover comprises inserting the tray through a frame coupled to the recessed portion.
 22. The method of claim 21, wherein inserting the tray through the frame coupled to the recessed portion comprises folding the substantially planar portion of the tray at a plurality of score lines extending between the cutout portions around the handle feature. 